Airbag assembly with tethered reaction surface and cushion configured to permit forward head rotation

ABSTRACT

An airbag assembly for mounting above an occupant in a vehicle includes an airbag housing and an airbag cushion. The airbag cushion is connected to the housing and is deployable from an uninflated state to an inflated state. The airbag cushion includes a forward portion and a rearward portion. The forward portion is positioned closer to the occupant than the rearward portion when the airbag cushion is in the inflated state. The forward portion is also separated from the rearward portion by a void. The void configured to cause a head of the occupant to rotate forward relative to a torso of the occupant when the occupant contacts the airbag cushion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/825,665 filed on Nov. 29, 2017. The entire disclosure of the aboveapplication is incorporated herein by reference.

INTRODUCTION

The information provided in this section is for the purpose of generallypresenting the context of the disclosure. Work of the presently namedinventors, to the extent it is described in this section, as well asaspects of the description that may not otherwise qualify as prior artat the time of filing, are neither expressly nor impliedly admitted asprior art against the present disclosure.

The present disclosure relates to airbag assemblies with tetheredreaction surfaces and cushions that are configured to permit forwardhead rotation.

Airbag assemblies typically include an airbag cushion and an inflatorthat is operable to inflate the airbag cushion. The inflator includes atube having a closed end containing a gas source and an open endopposite the closed end and positioned within the airbag cushion. Thegas source typically includes an electric igniter and at least one of anexplosive charge such as a solid propellant and a stored gas chargestored under high pressure. The electric igniter ignites the solidpropellant and/or releases the stored gas in response to an electroniccontrol signal, which produces a gas that inflates the airbag cushion.

Airbag assemblies are often mounted in a dashboard of a vehicle, in aseat of a vehicle and/or in a steering wheel of a vehicle. Some airbagassemblies, however, are mounted to a roof of a vehicle and inflate in adownward manner toward the occupants in the vehicle. Such airbagassemblies are commonly referred to as roof-mounted or overhead airbagsystems.

SUMMARY

In one example in accordance with the present disclosure, an airbagassembly is configured for mounting above an occupant in a vehicle. Theexample airbag assembly includes an airbag housing that is configured toenclose an airbag cushion when the airbag cushion is in an uninflatedstate. The airbag cushion is connected to the airbag housing and isconfigured to project outward from the airbag housing when the airbagcushion inflates from the uninflated state to an inflated state. Theexample airbag assembly also includes a tether connected at a firstattachment point and connected to the airbag cushion at a secondattachment point. The first attachment point is located horizontallycloser to the occupant than the second attachment point when the airbagcushion is in the inflated state such that the tether limits movement ofthe airbag cushion in a direction away from the occupant.

In one aspect, the first attachment point is located on the airbaghousing.

In one aspect, the first attachment point is located on a roof of thevehicle.

In one aspect, the tether is positioned inside the airbag cushion.

In one aspect, the tether is stitched to the airbag cushion at thesecond attachment point.

In one aspect, the tether is connected to the vehicle at a thirdattachment point. The tether wraps around an exterior surface of theairbag cushion between the first attachment point and the thirdattachment point.

In one aspect, the example airbag assembly also includes a secondtether. The second tether is connected to the vehicle at the firstattachment point and is connected to the airbag cushion at a sideattachment point. The side attachment point is positioned on the airbagcushion on a lateral side of the airbag cushion not facing the occupant.

In one aspect, the airbag housing includes a door. The door may beoperable in a closed state and in an open state. The door may cover theairbag cushion when the airbag cushion is positioned inside the airbaghousing in the uninflated state and may move away from the airbaghousing to permit the airbag cushion to project outward from the airbaghousing when the airbag cushion inflates to the inflated state. Thetether is connected to the door causing the door to be positioned on aside of the airbag cushion away from the occupant to limit movement ofthe airbag cushion in the direction away from the occupant when theairbag cushion is in the inflated state.

In one aspect, the door includes a door tether attachment bracketrigidly fixed thereto. At least a portion of the door tether is routedthrough the door tether attachment bracket to retain the door tether tothe door.

In one aspect, the airbag cushion includes at least one of a tetheredvent and a pyrotechnic vent.

In one aspect, the airbag cushion includes a tethered vent that isconfigured to move from an open position to a closed position when theairbag cushion inflates to the inflated state and to not move from theopen position to the closed position when an obstacle blocks the airbagcushion from inflating to the inflated state.

In one aspect, the airbag cushion includes a pyrotechnic vent configuredto move from a closed position to an open position after a predeterminedamount of time has elapsed since inflation of the airbag cushion or adoor of the vehicle has been opened.

In one aspect, the example airbag assembly also includes a tethersupport. The tether support connected to the airbag cushion at thesecond attachment point to reinforce a region of the airbag cushion atthe second attachment point.

In one aspect, the tether support is positioned between the tether andthe airbag cushion.

In one aspect, the tether support is positioned inside the airbagassembly.

In one aspect, the airbag cushion includes a lower portion and an upperportion. The lower portion is positioned closer to the occupant than theupper portion. The upper portion and the lower portion permitting a headof the occupant to rotate forward relative to a torso of the occupantwhen the occupant contacts the airbag cushion.

In one aspect, the airbag cushion includes a void between inflatedportions of the airbag cushion when the airbag is in the inflated state.The void permits a head of the occupant to rotate forward relative to atorso of the occupant when the occupant contacts the airbag cushion.

In one aspect, a first portion of the airbag cushion is connected to asecond portion of the airbag cushion. The first portion can be rolled orfolded back onto a second portion of the airbag cushion to form thevoid.

In one aspect, the airbag cushion includes a plurality of longitudinalchambers configured to stiffen the airbag cushion.

In another example in accordance with the present disclosure, an exampleairbag assembly can be mounted in a roof of a vehicle above and forwardof an occupant. The example airbag assembly includes an airbag housingand an inflator connected to the airbag housing. The example airbagassembly also includes an airbag cushion connected to the airbag housingand in fluid communication with the inflator. The airbag cushionincludes a lower portion and an upper portion and is operable in anuninflated state and in an inflated state. The airbag cushion inflatesfrom the uninflated state to the inflated state when gas is released bythe inflator. When the airbag cushion is in the inflated state, thelower portion is positioned at a first vertical height relative to theroof of the vehicle to engage a torso of the occupant and the upperportion is positioned at a second vertical height relative to the roofof the vehicle to engage a head of the occupant. The upper portion andthe lower portion permit the head of the occupant to rotate forwardrelative to the torso of the occupant when the occupant contacts theairbag cushion.

The example airbag assembly also includes an external tether connectedto the roof of the vehicle at a first attachment point and to the airbagcushion at a second attachment point. The second attachment point islocated below the first attachment point and at a horizontal positionfurther away from the occupant than the first attachment point such thatthe tether extends diagonally downward and away from the firstattachment point to the second attachment point along an exteriorsurface of the airbag cushion when the airbag cushion is in the inflatedstate.

Further areas of applicability of the present disclosure will becomeapparent from the detailed description, the claims and the drawings. Thedetailed description and specific examples are intended for purposes ofillustration only and are not intended to limit the scope of thedisclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is an illustration of example airbag assemblies in a vehicle inaccordance with the present disclosure;

FIG. 2 is a cut-away illustration of an example airbag assembly inaccordance with the present disclosure;

FIG. 3 is a cut-away illustration of another example airbag assembly inaccordance with the present disclosure;

FIGS. 4A-C are illustrations of example alternative attachments of atether to a door that can be used in airbag assemblies of the presentdisclosure;

FIG. 5 is a sectional view of an example airbag assembly of the presentdisclosure showing an internal tether and the attachment of an airbagcushion to an airbag housing;

FIG. 6 is an illustration of an airbag assembly packaged for insertioninto the airbag housing;

FIG. 7A is an exploded view of an example airbag assembly in accordancewith the present disclosure;

FIG. 7B is a view of the example airbag assembly of FIG. 7A with anexample alternate cross-sectional profile;

FIG. 7C is a cross-sectional view of an example profile of the airbag ofFIG. 7B;

FIG. 7D is a cross-sectional view of another example profile of theairbag of FIG. 7B;

FIG. 8 is an exploded view of an example structure of the airbag cushionof FIG. 7A;

FIG. 9 is an exploded view of another example airbag assembly inaccordance with the present disclosure;

FIG. 10 is a view of the airbag cushion of FIG. 9 shown at anintermediate stage of manufacture showing an example structure of theairbag cushion;

FIG. 11 is an illustration showing an example shaping tether;

FIG. 12 is an illustration showing an alternative shape of an airbagcushion of the present disclosure;

FIG. 13 is a cut-away illustration showing an example shaping tether;

FIG. 14 is a cut-away illustration showing another example shapingtether;

FIG. 15 is a cut-away illustration showing another example shapingtether;

FIG. 16 is a cut-away illustration showing another example shapingtether;

FIG. 17 is a cut-away illustration showing another example shapingtether;

FIG. 18A is an illustration of an example tethered vent in an openposition that can be used in an airbag assembly of the presentdisclosure;

FIG. 18B is an illustration of the tethered vent of FIG. 18A in a closedposition that can be used in an airbag assembly of the presentdisclosure;

FIG. 19A is an illustration of an example pyrotechnic vent in an openposition that can be used in an airbag assembly of the presentdisclosure;

FIG. 19B is an illustration of the example pyrotechnic vent of FIG. 19Bin the closed position that can be used in an airbag assembly of thepresent disclosure;

FIG. 20 is an illustration of another example airbag assembly inaccordance with the present disclosure;

FIG. 21 is an illustration of another example airbag assembly inaccordance with the present disclosure; and

FIG. 22 is an illustration of a vehicle with example airbag assembliesin accordance with the present disclosure.

In the drawings, reference numbers may be reused to identify similarand/or identical elements.

DETAILED DESCRIPTION

Existing airbag assemblies are often mounted in dashboards, in seats orin steering wheels of vehicles. In such circumstances, the airbagcushions of these airbag assemblies inflate toward an occupant of thevehicle from the dashboard, seat or steering wheel. When the occupantcontacts the airbag cushion, the airbag cushion is compressed betweenthe occupant and the dashboard, seat or steering wheel to absorb energy.

In roof-mounted or overhead airbag assemblies, the airbag cushion ofteninflates downward toward the occupant from the roof or overheadstructure in the vehicle. In some instances, the airbag cushion of theoverhead airbag assembly is positioned between an occupant and anotherstructure in the vehicle such as a dashboard, a windshield, a seat or asteering wheel. In such instances, the airbag cushion is compressedbetween the occupant and the dashboard, windshield, seat or steeringwheel and can perform similarly to non-overhead airbag assemblies.

In other instances, however, an overhead airbag assembly may be inflateddownward toward an occupant of a vehicle in a location where no suitablestructure exists in the vehicle that the inflated airbag cushion can becompressed against when the occupant contacts the airbag cushion. Insuch instances, the overhead airbag cushion can be said to lack asuitable reaction surface. Without a suitable reaction surface, theinflated airbag cushion moves away from an occupant without absorbingenergy when the occupant contacts the airbag cushion. The airbagcushion, without a suitable reaction surface, can be pushed aside ordisplaced without absorbing energy as intended.

In such instances where the geometry or structure of a vehicle lacks asuitable external reaction surface (e.g., a dashboard, a windshield, aseat, or a steering wheel), an airbag assembly of the present disclosurecan include one or more tethers that are positioned to serve as areaction surface for the airbag cushion. The one or more tethers areconnected to the airbag cushion and to a rigid structure in the airbagassembly and/or in the vehicle. The one or more tethers restrict themovement of the inflated airbag cushion when an occupant contacts theairbag cushion.

In other example airbag cushions in accordance with the presentdisclosure, the airbag cushions are shaped in a manner to reduce theforces and moment on the neck of an occupant when the occupant engagesthe airbag cushion. The airbag cushions can include a curved portionand/or a hollow portion that can permit the airbag cushion to deflect ina manner that permits the head of an occupant to pivot forward whileabsorbing energy when the occupant engages the airbag cushion.

With reference now to FIG. 1, a vehicle 20 includes a roof 22 and afloor 24 defining a vehicle cabin 26. The vehicle cabin 26 includes twoseats 28 and two occupants 30, 32. In this example vehicleconfiguration, the occupants 30, 32 are facing one another. The exampleairbag assemblies of the present disclosure, however, can be used inother vehicles or other environments in which the occupants 30, 32 donot face each and/or there are more or less than two occupants. Inaddition, the airbag assemblies of the present disclosure can beextended laterally (i.e., cross-vehicle) to cover more than one seatingposition. For example, the airbag assemblies of the present disclosurecan be used to cover two or three laterally adjacent occupant seatingpositions.

As shown, a first example airbag assembly 40 includes an airbag housing42, an inflator 44, an airbag cushion 46, a door tether 48, a wraptether 50 and a side tether 52. The airbag housing 42, in this example,includes a plurality of walls 54 and a door 56. The airbag housing 42 isconfigured such that the airbag cushion 46 can fit inside the airbaghousing 42 when the airbag cushion 46 is in an uninflated state. Asshown in FIG. 6, for example, the airbag cushion 46 can be folded,rolled or otherwise packaged when it is in the uninflated state andinserted into the airbag housing 42. As shown in FIG. 6, the airbagcushion 46, in one example, is configured as a roll 47 so that theinitial inflating portion 49 is adjacent the occupant and the laterfilling rolled portion 51 is positioned on an opposite side than theinitial inflating portion 49. In this manner, if the deployment of theairbag cushion 46 is partially obstructed, the airbag cushion 46 wouldroll out in front of the occupant and not over or behind the occupant'shead. In other examples, the airbag cushion can be fully rolled ormostly rolled with some type of fold-over, tuck or accordion foldcomprising part of the fold. Prior to folding the airbag cushion 46along its length, the airbag cushion 46 can be folded laterally tocoincide with a width of the airbag housing 42 with one or moreaccordion folds, tuck folds or roll folds.

The door 56 of the airbag housing 42 is sized to span across the walls54 to enclose the airbag housing 42. The door 56 is attached to thewalls 54 of the airbag housing 42 and can move from a closed position(not shown) to an open position as shown in FIG. 1. The door 56 can beattached via a living hinge or other mechanism such that it can movefrom the closed position to the open position when the airbag cushion 46is inflated. Alternatively, the door 56 can be mounted to componentsadjacent to the airbag assembly 40. In other examples, an airbagassembly of the present disclosure can be mounted as a passenger airbagor a seat mounted airbag and have the door 56 positioned on theinstrument panel or the seat trim, respectively. An airbag assembly thatincludes an inflator and an airbag cushion can be wrapped with a softmaterial cover with a weak region or a tear seam. In such examples, thesoft material cover is the airbag housing as contemplated herein.

The inflator 44, in this example, is mounted to the airbag housing 42.The inflator 44 is in fluid communication with the airbag cushion 46.The inflator 44 can be any suitable inflator that includes a gas sourcethat can rapidly inflate the airbag cushion 46. For example, theinflator 44 can be a pyrotechnic, compressed gas or hybrid inflator. Theinflator 44 rapidly releases a gas to inflate the airbag cushion 46 inresponse to receiving an electronic control signal.

As shown in the example of FIG. 1, the airbag cushion 46 is in theinflated state and has projected away from the airbag housing 42 uponbeing inflated with gas by the inflator 44. In this example, the airbagcushion includes an extension portion 58, an upper portion 60 and alower portion 62. The extension portion 58 is positioned adjacent andbelow the airbag housing 42 and contacts the door 56. The extensionportion 58, the upper portion 60 and the lower portion 62 are fluidlyconnected to one another such that they are inflated together by the gasemitted by the inflator 44. In this example, the extension portion 58,the upper portion 60 and the lower portion 62 are joined together toform a single cavity that is filled with the gas from the inflator 44.In other examples, the airbag cushion 46 can include separate chambersjoined together to form the airbag cushion 46.

The airbag cushion 46 also includes a void 64. The void 64 is created byportions of the airbag cushion 46 that are spaced apart from oneanother. The void 64 can have any suitable shape. In the example shown,the void 64 has an elongated rounded shape. The void 64 includes a voidshaping tether 66 that can be stitched or otherwise joined to the airbagcushion 46 in the void 64. The void shaping tether 66 is joined to theairbag cushion 46 on opposite sides of the void 64 to maintain a desiredsize and/or shape of the void 64 when the airbag cushion 46 is in theinflated state. The void shaping tether 66 can be made of any suitablematerial such as a woven or non-woven fabric. The void shaping tether 66can be made of material the same as or similar to the material used toform the airbag cushion 46. The void shaping tether 66 can also be usedin conjunction with other shaping tethers as described below.

The upper portion 60 of the airbag cushion 46 is positioned at avertical height from the floor 24 such that a head of the occupant 30 islocated opposite the upper portion 60. The lower portion 62 ispositioned at a vertical height from the floor 24 such that a torso ofthe occupant 30 is located opposite the lower portion 62. The void 64 ispositioned behind (or away from the occupant 30) the upper portion 60.With this structure, the head of the occupant 30 can rotate forwardrelative to the torso of the occupant as the void compresses and theairbag cushion 46 pivots slightly away from the occupant 30 about itsmounting location. In this manner, the forces and moment on the neck ofthe occupant 30 can be reduced.

To further assist in this kinematic effect, the lower portion 62 ispositioned closer to the occupant 30 than the upper portion 60. Thiscreates an angled occupant contact surface that further permits the headof the occupant 30 to rotate relative to the torso of the occupant 30when the occupant 30 contacts the airbag cushion 46. The airbag cushion46, including the extension portion 58, the upper portion 60 and thelower portion 62, can be made of any suitable flexible but generallynon-stretchable material that reasonably resists the leakage of gasthrough the material so that the airbag cushion can be inflated from theuninflated state to the inflated. The material can be a woven ornon-woven fabric material and can include one or more layers or one ormore coatings.

As can be appreciated, the vehicle 20, in this example, does not includea rigid structure that is located behind the airbag cushion 46. As such,the airbag assembly 40, in this example, does not include an externalreaction surface to support the airbag assembly 40 when the occupant 30contacts the airbag cushion 46. Instead, the example airbag assembly 40includes the door tether 48, the wrap tether 50 and the side tether 52.The door tether 48, the wrap tether 50 and the side tether 52 supportthe airbag cushion 46 and limit movement of the airbag cushion 46 in adirection away from the occupant 30 so that the airbag cushion 46 cansufficiently absorb energy when the occupant 30 contacts the airbagcushion 46. As can be further appreciated, without the door tether 48,the wrap tether 50 and/or the side tether 52, the airbag cushion 46would significantly move away from the occupant 30 and rotate about itsmounting location to the roof 22 when the occupant 30 contacts theairbag cushion 46. The door tether 48, the wrap tether 50 and/or theside tether 52 resist this movement and rotation.

The door tether 48, the wrap tether 50 and the side tether 52 can bemade of any suitable flexible but generally non-stretchable materialthat can be attached (as will be described) and move with the airbagcushion 46 when the airbag cushion 46 inflates from the uninflated stateto the inflated state. In the example shown, the door tether 48, thewrap tether 50 and the side tether 52 are made of a woven fabricmaterial. In other examples, other non-woven or other materials can alsobe used.

The door tether 48, in this example, is connected to the airbag housing42 at a first attachment point 68. The door tether 48 is also connectedto the door 56 at a door attachment point 70. As shown, the firstattachment point 68 is located on or near the side of the airbag housing42 closest to the occupant 30. The door attachment point 70 ispositioned on the door 56. Since the door 56 moves to the open positionby rotating away from the occupant 30, the door tether 48 extendsdiagonally downward from the roof 22 and away from the occupant 30. Whenthe airbag cushion 46 is in the inflated state, the door tether 48 isfully extended and significantly reduces further movement of the door56. In the example shown, at full extension the door tether 48 positionsthe door 56 at an angle to the airbag housing 42. In other examples, thedoor 56 can be positioned vertically at full extension of the doortether 48.

The first attachment point 68 can be any suitable connection for thedoor tether 48. As shown in FIG. 2, the first attachment point 68 can bea connector plate 67 with an opening 69. In one example, the connectorplate 67 is part of the base panel 150. In other examples, such as theone shown in FIG. 3, the connector plate 67 is part of another componentof the airbag assembly 40. In still other examples, the connector plate67 and/or first attachment point 68 is directly connected to the vehicle20. Whether directly or indirectly, the first attachment 68 is securedto the vehicle 20 so that the door tether 48, in turn, is secured to thevehicle 20. The door tether 48 can be routed through the opening 69 ofthe connector plate 67 and fixed thereto by stitching the door tether 48or by using a suitable fastener, clip, or other connector.

The door attachment point 70 can also be any suitable connection tosecure the door tether 48. As further shown in FIG. 2, the doorattachment point 70 can be a bracket mounted or otherwise secured to thedoor 56. Other suitable attachments can be used to secure the doortether 48 to the door 56. FIGS. 4A-C illustrate other examples of thedoor attachment point 70. The door attachment point 70 can be a separatebridge portion 72 that is stitched, heat staked, welded or otherwisemechanically secured to the door 56. The door tether 48 can be routedthrough the bridge portion 72 to secure the door tether 48 to the door56.

In another example shown in FIG. 4B, the door attachment point 70 caninclude a bridge portion 74 that has a similar shape to that of bridgeportion 72. In this example, the bridge portion 74 is integrally moldedinto the door 56. The bridge portion 74 can be made of a materialdifferent from that of the door 56. The bridge portion 74 can beinserted into a fixture or mold such that the door 56 is formed aroundthe bridge portion 74. In other examples, the door 56 can be formed suchthat the bridge portion 74 is formed with the door 56.

In yet another example shown in FIG. 4C, the door attachment point 70can include two projections 76 that extend from the door 56. The doortether 48, in this example, is connected at the two projections 76. Inother examples, the door tether 48 can be a continuous length ofmaterial that is routed through both the projections 76. The projections76 can be elements of a larger bracket 78 that is integrally formed withor molded into the door 56. In addition, the projections 76 can beseparate brackets within the door 56.

In some examples of the airbag assembly 40, the door tether 48 is asingle length of material that is routed through the first attachmentpoint 68 and through the door attachment point 70. As such, the doortether 48 may be permitted to slide through the first attachment point68 and/or the door attachment point 70. In other examples, the doortether 48 is connected at the first attachment point 68 and/or the doorattachment point 70 such that the door tether 48 cannot slide throughthe attachment point. In either instance, the door tether 48 limits themovement of the door 56 when the airbag cushion 46 is in the inflatedstate. As can be seen, the extension portion 58 of the airbag cushion 46contacts the door 56 and limits movement of the airbag cushion 46 frommoving away from the occupant 30 when the occupant 30 contacts theairbag cushion 46.

The wrap tether 50 is also connected at the first attachment point 68.As previously described, the first attachment point 68 can be part ofthe base panel 150 or otherwise directly or indirectly connected to thevehicle 20. As shown in FIGS. 1 and 2, when the airbag cushion 46 is inthe inflated state, the wrap tether 50 extends diagonally downward fromthe roof 22 and away from the occupant 30. The wrap tether 50 wrapsaround the airbag cushion 46 and connects to an attachment point locatedon an opposite side of the airbag assembly 40 from the first attachmentpoint 68. The wrap tether 50, in this example, is connected to theairbag cushion 46 on a back surface 80 (i.e. the surface positioned awayfrom the occupant 30). The wrap tether 50 is stitched to the backsurface 80. In this example, the wrap tether 50 wraps around the airbagcushion 46 at a location below the door 56 and the below the door tether48. In other examples, the wrap tether 50 can be positioned at differentlocations on the airbag cushion 46.

The airbag assembly 40, as shown in the example of FIGS. 1 and 2, alsoincludes the side tether 52. The side tether 52 is a length of flexiblebut generally non-stretchable material that extends from the firstattachment point 68 to a side surface 82 of the airbag cushion 46. Ascan be appreciated, a second side tether (not shown) can be positionedon the opposite side surface from side surface 82 such that the airbagassembly 40 includes two opposing side tethers 52. The side tetherextends diagonally downward from the roof 22 and away from the occupant30. In this example, the side tether 52 is attached to the airbagcushion 46 at a side attachment point 84 that is located verticallybelow the door tether 48 and the wrap tether 50. In other examples, theside attachment point 84 can be located at other locations on the sidesurface 82. In still other examples, the side tether 52 can wrappartially around the airbag cushion 46 and be attached on the backsurface 80.

As further shown in FIGS. 1 and 2, the side tether 52 can include anenlarged attachment pad 86 at the side attachment point 84. Theattachment pad 86 in this example is square or rectangular in shape butother configurations can also be used. In this example, the side tether52 is stitched to the airbag cushion 46 at the side attachment point 84.The attachment pad 86 provides a large contact surface between the sidetether 52 and the airbag cushion 46 so that a series of stitches can beused to securely attach the side tether 52 to the airbag cushion 46.

In the example shown, the door tether 48, the wrap tether 50, the sidetether 52 and the door 56 provide reaction surfaces to limit themovement of the airbag cushion 46 in a direction away from the occupant30. In other examples of the airbag assembly 40, various combinations ofthe door tether 48, the wrap tether 50, the side tether 52 and/or thedoor 56 can be used to limit the movement of the airbag cushion 46. Inaddition, multiples of the same type of tether can be used. For example,another airbag assembly 40 can use only one wrap tether 50. In anotherexample, more than one side tethers 52 can be used. Various iterationsof the previously described tethers can be used to accommodate differentgeometries and configurations of the vehicle cabin 26.

FIG. 1 depicts another example airbag assembly 100. In this example, theairbag assembly 100 extends downward from the roof 22 in front of theoccupant 32. The airbag assembly 100 can include many similar featuresto that previously described with respect to the airbag assembly 40. Theexample airbag assembly 100, however, includes some features that aredifferent or alternatively configured to that previously described. Itshould be appreciated that the features of the airbag assembly 40 andthe features of the airbag assembly 100 are not mutually exclusive andthat the features can be interchanged or added as may be desiredaccording the specific needs of the vehicle environment.

The example airbag assembly 100 includes an airbag housing 102, aninflator 104, an airbag cushion 106, a wrap tether 108 and a side tether110. The inflator 104 is positioned inside the housing 102 and isconfigured to inflate the airbag cushion 106 from an uninflated state toan inflated state as previously described.

The airbag housing 102, is similar to that previously described, and isconfigured to enclose the airbag cushion 106 when the airbag cushion 106is in the uninflated state. The airbag housing 102 includes a door 112.The door 112 is movably connected to the airbag housing 102 such thatthe door 112 can move to permit the airbag cushion 106 to inflate andproject downward from the airbag housing 102. The door 112 can include aliving hinge and one or more breakable seams to permit the movement ofthe door 112 relative to the airbag housing 102. As shown in the exampleof FIG. 1, the door 112 can bend at or near the airbag housing 102 andflex away from the occupant 32 and toward the roof 22 when the airbagcushion 106 inflates.

The airbag cushion 106, in this example, can be constructed of amaterial similar to that previously described. The airbag cushion 106,in this example, projects downward from the airbag housing 106 along theextension portion 114. The airbag housing is rolled or folded backupwards at the lower portion 116 and the upper portion 118 is connectedto the extension portion 114. The upper portion 118 can be connected viastitching or other suitable attachment method to the extension portion114 with an attachment tab 120. The attachment tab 120 can be attachedto a side of the upper portion 118 that is located away from theoccupant 32 (as shown in FIG. 1) or to a side of the upper portion 118that is facing the occupant 32.

The extension portion 114 is spaced apart from the upper portion 118 tocreate a void 122. The upper portion 118 of the airbag cushion 106 ispositioned at a vertical height from the floor 24 such that a head ofthe occupant 32 is located opposite the upper portion 118. The lowerportion 116 is positioned at a vertical height from the floor 24 suchthat a torso of the occupant 32 is located opposite the lower portion116. The void 122 is positioned behind (or away from the occupant 32)the upper portion 118. With this structure, the head of the occupant 32can rotate forward relative to the torso of the occupant as the voidcompresses and the airbag assembly 100 pivots slightly away from theoccupant 32 around its mounting location at the roof 22. In this manner,the forces and moment on the neck of the occupant 32 can be reduced.

To further assist in this kinematic effect, the lower portion 116 ispositioned closer to the occupant 32 than the upper portion 118. Thiscreates an angled occupant contact surface that further permits the headof the occupant 32 to rotate relative to the torso of the occupant 32when the occupant 32 contacts the airbag cushion 106.

As shown in the example of FIGS. 1 and 3, the airbag cushion 106includes an optional reaction foot 124. The reaction foot 124 is aportion of the airbag cushion 106 that projects away from the occupant32 at or near the roof 22. In this example, the reaction foot 124 is anintegral part of the airbag cushion and is formed of the same materialas the other regions of the airbag cushion 106 (i.e., the extensionportion 114, the lower portion 116 and the upper portion 118). In otherexamples, the reaction foot 124 can be a separate chamber or formed froma separate piece (or pieces) of material that is attached to the airbagcushion 106.

The reaction foot 124 is fluidly connected to a central chamber of theairbag cushion 106 such that the reaction foot 124 inflates along withthe airbag cushion 106. When the airbag cushion 106 is in the inflatedstate, the reaction foot 124 projects away from the occupant and, inthis example, contacts the roof 22 to limit the movement of the airbagcushion 106 in a direction away from the occupant 32. In the exampleshown, the reaction foot 124 indirectly contacts the roof 22 since thedoor 112 is positioned between the reaction foot 124 and the roof 22when the airbag cushion 106 is in the inflated state. In other examples,the reaction foot 124 can be positioned directly adjacent the roof 22 orcan be supported (directly or indirectly) by another structure in thevehicle cabin 26 such as a support pillar, an overhead storagecompartment, console, or the like.

As shown in FIG. 3, the airbag cushion 106 can include a foot tether126. The foot tether 126 is a length of flexible but generallynon-stretchable material that limits the movement of the reaction foot124 or causes the reaction foot 124 to maintain a desired shape. In thisexample, the foot tether 126 is a rectangular piece of flexible butgenerally non-stretchable material stitched to the portion of thereaction foot 124 adjacent to the door 112 and to a back wall 128 of theairbag cushion 106. The foot tether 126 is positioned inside thereaction foot 124 and/or the airbag cushion 106. In other examples, thefoot tether 126 can be connected at other locations and/or positionedexternally to the reaction foot 124. In addition, the foot tether 126can be connected to the airbag cushion 106 using other suitable methodsof attachment such as by weaving the foot tether 126 into the airbagcushion 106.

The airbag cushion 106, in the example shown, includes the wrap tether108 and the side tether 110 in addition to the reaction foot 124 tolimit the movement of the airbag cushion 106 in a direction away fromthe occupant 32. The wrap tether 108 is similar to the wrap tether 50previously described in that it is an elongated piece of flexible butgenerally non-stretchable material that is connected at a firstattachment point 130 and wraps around the airbag cushion 106. As shownin FIG. 1, the first attachment point 130 may be positioned on theairbag housing 102. Alternatively, as shown in FIG. 3, the firstattachment point 130 may be positioned externally to the airbag housing102. As shown, the wrap tether 108 is connected to a connector plate132. The connector plate 132, in this example, is a steel member with anopening for accepting the wrap tether 108. The wrap tether 108 can beconnected to the connector plate 132, for example, by looping the wraptether 108 through the opening and stitching (or otherwise connecting)the wrap tether 108 to itself to form a loop. The connector plate 132can be welded, bolted or otherwise connected to a structural member ofthe vehicle 20 such as a roof rail, roof structure, pillar or the like.Any other tether attachment points described herein can use a similarattachment as that shown and described with respect to the wrap tether108 and the connector plate 132.

The wrap tether 108, in the example shown, wraps around the back wall128 of the airbag cushion 106 and is connected to an attachment pointlocated on the opposite side of the airbag cushion 106 from the firstattachment point 130. The wrap tether 108 can also be connected (viastitching, adhesive, or other suitable method) to the airbag cushion 106at the back wall 128. In the example shown, a back seam 134 connects thewrap tether 108 to the airbag cushion 106. As further shown in FIG. 3, aback reinforcement 136 is positioned, in this example, between the wraptether 108 and the back wall 128 of the airbag cushion 106. The backreinforcement 136 is a flexible panel of material connected to theairbag cushion 106 at a location where the wrap tether 108 contacts oris attached to the airbag cushion 106. The back reinforcement 136 canstiffen the airbag cushion 106 at a localized portion of the airbagcushion. The back reinforcement 136 can also distribute the forcestransmitted between the wrap tether 108 and the airbag cushion 106. Thedistribution of forces can prevent localized ripping or tearing of theairbag cushion and assist in limiting the airbag cushion 106 from movingaway from the occupant 32.

The airbag assembly 100, in the example shown, also includes the sidetether 110. The side tether 110 can be similar to the side tether 52previously described. In this example, the side tether 110 is a lengthof flexible but generally non-stretchable material. The side tether 110is attached at the first attachment point 130 and extends to a sideattachment point 138 on a side surface 140 of the airbag cushion 106. Inone example shown in FIG. 3, the side tether 110 widens between thefirst attachment point 130 and the side attachment point 138. As such,the side tether includes an enlarged footprint at the side attachmentpoint 138. The enlarged footprint distributes the forces at the sideattachment point 138 over a larger surface area to prevent ripping,tearing or other failures at the side attachment point 138.

As shown in FIG. 3, the side tether 110 is positioned on an outsidesurface of the airbag cushion 106. The airbag assembly 100 can alsoinclude a side reinforcement 142 positioned on an inside surface 144 ofthe airbag cushion 106. The side reinforcement 142 is a panel ofmaterial positioned on the inside surface of the airbag cushion 106 atthe side attachment point 138. The side tether 110 can be connected tothe airbag cushion 106 by stitching the side tether 110 through theairbag cushion 106 and through the side reinforcement 142 as shown. Inthis manner, the side reinforcement can provide added stiffness to theairbag cushion 106 and/or prevent ripping, tearing or other failure atthe side attachment point 138. The side reinforcement 142 can extendalong an inner surface of the airbag cushion 106 toward the airbaghousing 102 as shown. In other examples, the side tether 110 can bepositioned inside the airbag cushion 106 (rather than on the externalsurface of the side surface 140 as shown) and have a similar shape andconfiguration as that shown for the side reinforcement 142.

As shown in FIG. 5, the airbag cushion 106 (or the airbag cushion 46) isconnected to the airbag housing 102, in this example, by securing one ormore flaps on the airbag cushion 106 to the airbag housing 102. Asshown, the airbag cushion 106 includes a first flap 146 and a secondflap 148. The first flap 146 and the second flap 148 are connected tothe base panel 150 of the airbag housing 102. Any suitable method ofattachment can be used. In this example, two fasteners 152 are insertedthrough a mounting plate 154, the first flap 146 and the second flap 148and secured to the base panel 150. The first flap 146 and the secondflap 148 are secured in position between the base panel 150 and themounting plate 154. In other examples, the airbag cushion 106 can beconnected to the airbag housing 102 without the mounting plate 154. Asshown in FIG. 5, the inflator 104 is secured to one of the fasteners 152such that the inflator 104 is positioned inside the central chamber ofthe airbag cushion 106. In this position, the inflator 104 can emit agas to inflate the airbag cushion 106 from the uninflated state to theinflated state.

The airbag housing 102 can include one or more mounting studs 156. Inthe example shown in FIG. 6, the airbag housing 102 includes fourmounting studs 156 that project away from the airbag housing 102. Theairbag housing can then be secured at a desired location in the vehicle20 (such as to the roof 22) by inserting the mounting studs 156 into asupport structure of the vehicle 20 and securing the mounting studs 156to the support structure.

Referring back to FIG. 5, the airbag cushion 106, in this example,includes an angled internal tether 158. The angled internal tether 158is a thin piece of flexible but generally non-stretchable material sewnor otherwise attached to the airbag cushion 106. The internal tether158, in this example, is attached to the airbag cushion 106 at a firstend 160 and at a second end 162. The first end 160 is positioned at ornear the airbag housing 102 (either adjacent to or not adjacent to themounting plate 154) and the second end 162 is positioned below the firstend 160 on an opposite internal side of the airbag cushion 106. As such,the internal tether 158 extends diagonally across the airbag cushion106. The internal tether 158 can maintain a desired shape of the airbagcushion 106 at the extension portion 114 of the airbag cushion 106 inthe region where the airbag cushion inflates out from the airbag housing102. In other examples, the airbag cushion 106 can include more than oneinternal tether 158 and/or other internal tethers with different shapes,sizes or attachment locations to shape or limit movement of the airbagcushion 106.

As shown in FIGS. 7A and 8, the airbag cushion 106 can be constructed ofmultiple panels sewn or otherwise joined together. In one example, theairbag cushion 106 includes a first side panel 164, a second side panel166, a first face panel 168, a second face panel 170, a first separatorpanel 172 and a second separator panel 174. The longitudinal edges ofthe first side panel 164 and the second side panel 166 are joined to thelongitudinal edges of the first face panel 168 and the second face panel170 to form the airbag cushion 106. The longitudinal edges can be sewntogether at seams that can be positioned inside (or outside) the centralchamber of the airbag cushion 106. The first side panel 164 and thesecond side panel 166, in this example, have a curved or J-shape. Whenthe first face panel 168 and the second face panel 170 are joined to thefirst side panel 164 and the second side panel 166, the resulting airbagcushion has the same curved or J-shaped profile as the first side panel164 and the second side panel 166. At a terminal end 176 of the airbagcushion 106, the lateral edges of the first face panel 168 and thesecond face panel 170 are joined together at terminal seam 178 to closethe airbag cushion 106 at the terminal end 176.

At the connecting end 180 of the airbag cushion 106, the airbag cushionincludes the first flap 146, the second flap 148, a third flap 182 and afourth flap 184. Once the inflator 104 and the mounting plate 154 havebeen inserted into the airbag cushion 106, the first flap 146, thesecond flap 148, the third flap 182 and the fourth flap 184 are foldedin an overlapping manner inwardly such that the openings in the flapsalign. As such, fasteners, studs 156 or other connecting members can beinserted through the aligned holes in the mounting plate 154, the flaps146, 148, 182, 184 and the base panel 150 to connect the airbag cushion106 to the airbag housing 102.

The airbag cushion 106 also includes the first separator panel 172 andthe second separator panel 174. The first separator panel 172 and thesecond separator panel 174, in this example, are connected inside theairbag cushion 106 between the first side panel 164 and the second sidepanel 166 to create longitudinal chambers inside the central chamber ofthe airbag cushion 106. As can be appreciated, the first separator panel172 and the second separator panel 174 are stitched along longitudinalseams 187 inside the airbag cushion 106. In the example shown, theairbag cushion 106 includes two separator panels. In other examples, theairbag cushion can include more or less than two separator panels tocreate more or less than three longitudinal chambers inside the airbagcushion 106.

The longitudinal chambers created by the first separator panel 172 andthe second separator panel 174 can help to evenly distribute the gasinside the airbag cushion 106. Additionally, the first separator panel172 and the second separator panel 174 assist in maintaining the shapeand contour of the airbag cushion 106. As described above, the firstseparator panel 172 and the second separator panel 174 have a curved orJ-shape as shown in FIG. 8. In other examples, the first separator panel172, the second separator panel 174, the first side panel 164 and thesecond side panel 166 can have substantially rectangular or elongatedshapes without the curved profile as shown. In such examples, the panelsare joined together to form an airbag cushion with a rectangularprofile. The rectangular-shaped airbag cushion 106 can then be rolled orfolded to have the curved or J-shape as shown in FIG. 7A.

As further shown in FIG. 7A, the airbag cushion 106 can include theattachment tab 120 that connects the terminal end 176 to the extensionportion 114 of the airbag cushion 106. In addition, the airbag cushion106 includes a shaping tether 186 that is connected inside the void 122to maintain the desired curved shape of the airbag cushion 106 when theairbag cushion 106 is in the inflated state. The shaping tether 186 is aflexible but generally non-stretchable piece of material stitched orotherwise connected to opposing surfaces of the first face panel 168inside the void 122. In this example, the shaping tether 186 is arectangular piece of material. In other examples, the airbag cushion 106can include more than one shaping tether 186 and/or shaping tethers 186of different shapes and configurations.

As shown in FIG. 7B, the airbag cushion 106 a can have an alternatecross-sectional profile. The airbag cushion 106 a, in one alternateexample, has two recessed portions 171 that are positioned between afirst side longitudinal chamber 173 and a second side longitudinalchamber 175. The recessed portions 171 are inset from the first sidelongitudinal chamber 173 and the second side longitudinal chamber 175.This example airbag cushion 106 a includes a first face panel 168 and asecond face panel 170. The first face panel 168 and the second facepanel 170 can be tethered, stitched or woven to create thecross-sectional profile as shown. The first face panel 168 can be spacedapart from the second side face panel 170 and be filled with gas afterthe airbag cushion 106 a inflates. The first face panel 168 can,alternatively, contact the second face panel 170 such that the firstpanel 168 is not spaced apart from the second face panel 170. The airbagcushion 106 a can also include a rib 177 or multiple ribs. The number ofribs affects the number of recessed portions. The rib 177 can connectbetween the first side longitudinal chamber 173 and the second sidelongitudinal chamber 175 at or near the location where an occupant'shead contacts the airbag cushion 106 a. Depending on how the first facepanel 168 and the second face panel 170 are attached to each other, therecessed portion 171 may not be inflated as shown in FIG. 7C. In anotherexample, the recessed portion may be inflated to a reduced thickness asshown in FIG. 7D. An optional tether 179 can be used to control theinflated thickness of the recessed portion 171. Likewise, similartethers can be used between the recessed portion 171 and the first sidelongitudinal chamber 173 and the second side longitudinal chamber 175.In still other examples, the recessed portion 171 can be divided intomultiple chamber positioned side-by-side. For instance, for a twochamber construction, tether 179 shown in FIG. 7D can be replaced withstitching between two outer walls.

As shown, the airbag cushion 106 a can have a side view shape and/orprofile similar to that shown in FIG. 7A. The airbag cushion 106 a, inthis example, has a curved or rounded side profile shape similar to theletter “J.” The terminal end 176 of the airbag cushion is attached tothe recessed portion 171 at or near the connecting end 180 with theattachment tab 120. The attachment tab 120 helps to create the void 122,as previously described. With the shape as shown in FIG. 7B, the airbagcushion 106 a has an internal volume that is less than the interiorvolume of the airbag cushion 106 shown in FIG. 7A. Since the airbagcushion 106 a has a smaller interior volume, the airbag cushion 106 acan inflate to the inflated state more quickly that the airbag cushion106 shown in FIG. 7A or can use a smaller, less heavy inflator with lessgas output.

As shown in FIGS. 9 and 10, another example construction of the airbagcushion 106 is shown. The geometry of the airbag cushion 106 is similarto that previously described. In this example, however, the airbagcushion 106 includes a first panel 188, a second panel 190, a firstcross tether 192, a second cross tether 194 and an end tether 196. Theairbag cushion 106 is constructed by stitching or otherwise connectingthe first panel 188 to the second panel 190 around a periphery of thepanels at a peripheral seam 198. The first panel 188 is also connectedto the second panel 190 along one or more longitudinal seams 200. As anoptional construction (not shown), the first panel 188 and the secondpanel 190 can be made of the same panel of material if the material isfolded over on itself. The longitudinal seams 200 are positioned betweenthe side edges of the first panel 188 and the second panel 190 andinside the peripheral seam 198. The longitudinal seams 200 can terminatewith a circular sewing pattern to reduce localized stresses wheninflated. As shown in FIG. 9, the longitudinal seams 200 partition theairbag cushion 106 into one or more longitudinal chambers when theairbag cushion inflates to the inflated state. As shown, the airbagcushion 106, in this example, is partitioned into three longitudinalchambers by two longitudinal seams 200. In other examples, more than (orless than) two longitudinal seams can be included to partition theairbag cushion into more than (or less than) three longitudinalchambers.

Similarly to example previously described, the airbag cushion 106 isfolded and/or rolled so that a terminal end 202 of the airbag cushion106 is placed at or near a series of flaps at the opposite end of theairbag cushion 106. The end tether 196 is stitched or otherwise attachedto a portion of the airbag cushion near the first flap 204, the secondflap 206, the third flap 208 and the fourth flap 210. This forms arounded shape (or J-shape) of the airbag cushion 106 with the void 122.The first cross tether 192 and the second cross tether 194 are attachedacross the void 122. The end tether 196, the first cross tether 192 andthe second cross tether 194 retain the airbag cushion 106 into therounded and/or folded shape with the void 122. The airbag cushion 106can also optionally include a shaping tether (such as shaping tether 186shown in FIG. 7A).

The airbag cushion 106 can also include one or more panels that havefabric with a weave direction that assists the airbag cushion 106 tohave the curved, rounded and/or folded shape as shown. For example, thefirst panel 188 includes a first weave direction 191 that is orientedwith fibers in longitudinal and perpendicular directions relative to theside edges. The second panel 190, in this example, includes a secondweave direction 193 that includes fibers oriented at a 45 degree anglerelative to the first weave direction. With such orientations, the firstpanel 188 is limited from stretching in the longitudinal direction dueto the first weave direction 191. The second panel 190, in comparison,is permitted to stretch in the longitudinal direction. Such relativeweave orientations can assist the airbag cushion 106 to form into thecurved, rounded and/or folded shape when the airbag cushion 106inflates.

The inflator 104 can be inserted into the airbag cushion 106 so that thestuds 195 protrude through the holes 197 and then the studs 195 can bepassed through the holes 199 in the airbag housing 102. In this manner,the inflator 104 and associated studs 195 hold the airbag cushion 106into the airbag housing 102 and the base panel 150 is not used. Aspreviously described, this example airbag cushion 106 can be rolled andor folded and inserted into the airbag housing 102. The airbag cushion106 can be secured to the airbag housing 102 by one or more fasteners(not shown in FIG. 9) that are inserted through the opening in the firstflap 204, the second flap 206, the third flap 208 and the fourth flap210. The fasteners secure the flaps, the inflator 104 and the mountingplate 154 inside the airbag housing 102.

The example airbag cushions 46, 106, as previously described, arestitched or otherwise connected together to create the structures asshown. In other examples, the airbag cushions can be woven together. Forexample, the first side panel 164, the second side panel 166, the firstface panel 168, the second face panel 170, the first separator panel 172and/or the second separator panel 174 can be woven together out of awoven material during manufacture rather than being separately made andthen connected together. Similarly, the first panel 188 and the secondpanel 190 can be woven together as a single component out of a wovenmaterial rather than being created separately and then stitchedtogether. In still other examples, a combination of woven panels andseparately connected panels can be used to create the airbag cushions106 previously described.

In other examples, the airbag cushions 46, 106 can include other shapes,configurations and/or tethers. As shown in FIG. 11, an example airbagcushion 212 can include a corner tether 214. The corner tether 214 is arectangular piece of flexible but generally non-stretchable materialconnected inside the void 216 of the airbag cushion 212. The cornertether 214 limits the movement of the airbag cushion 212 when the airbagcushion inflates to maintain a desired shape of the airbag cushion 212.

As shown in FIG. 12, another example airbag cushion 218 can include aleg 220. The leg 220 is a portion of the airbag cushion 218 thatprojects downward from the bottom curved portion of the airbag cushion218. The leg 220 can be directed toward or away from an occupant 30, 32.For example, the leg 220 can be directed downward from the airbagcushion 218 and provide a lower contact surface for an occupant's torso.

As shown in FIGS. 13 and 14, another example airbag cushion 222 caninclude an internal shaping tether 224. The internal shaping tether 224can span across the internal cavity of the airbag cushion 222 and beconnected to the internal surface of opposing side walls. In such anexample, the internal shaping tether 224 includes one or more apertures226. The apertures 226 permit gas to flow through the internal shapingtether 224 to permit the airbag cushion 222 to inflate. In anotherexample, as shown in FIG. 14, the airbag cushion 222 can include aseries of internal shaping tethers 228 a-c. The Internal shaping tethers228 are spaced apart from one another to permit gas to flow between theinternal shaping tethers 228. The internal shaping tethers 224, 228maintain a desired distance between opposing walls of the airbag cushion222 to maintain a desired shape of the airbag cushion 222.

As shown in FIGS. 15 and 16, still another example airbag cushion 230can include a bend tether 232. The bend tether 232 is a flexible butgenerally non-stretchable piece of material that has two angled portions236 that form an inverted V-shape. An apex 234 of the bend tether 232 isconnected to one side of the airbag cushion 230 and the opposite ends ofthe angled portions 236 are connected to the opposite side of the airbagcushion 230 at or around a bend in the airbag cushion 230. In thismanner, the bend tether 232 can maintain a bend, a corner or other shapeof the airbag cushion 230.

In one example, the bend tether 232 is a single rectangular piece ofmaterial that is shaped and connected inside the airbag cushion 230. Insuch an example, the bend tether 232 can include one or more apertures238 that permit gas to flow through the bend tether 232. In anotherexample, as shown in FIG. 16, a series of bend tethers 240 a-c, can beconnected inside the airbag cushion 230. The bend tethers 240 are spacedapart from one another inside the airbag cushion 230 to permit gas toflow between the bend tethers 240 when the airbag cushion is inflating.In the example shown, the airbag cushion 230 includes three bend tethers240. In other examples, more or less than three bend tethers 240 can beused to maintain a desired shape of the airbag cushion 230.

FIG. 17 shows another example of the airbag cushion 46. As previouslydescribed, the airbag cushion 46 includes the void shaping tether 66. Asshown, the airbag cushion 46 can also include one or more internalshaping tethers 242. In this example, the void shaping tether 66 and thepair of internal shaping tethers 242 are positioned in substantially thesame horizontal plane in the airbag cushion 46. In other examples, thevoid shaping tether 66 and the internal shaping tethers 242 can bepositioned in different planes or can be arranged at angles relative toone another. Various void shaping tethers 66 and internal shapingtethers 242 can be used to maintain a desired shape of the airbagcushion 46.

The airbag assemblies of the present disclosure can also include one ormore vents. The vents can be used to release gas that is containedinside the airbag cushion after the airbag cushion has inflated to theinflated state. It may be desirable to release the gas that is containedinside the airbag cushion to provide clearance for the occupant to exitthe vehicle after the airbag has inflated. In other circumstances it maybe desirable to include a vent in an airbag assembly in order to permitgas to escape from the airbag cushion is the airbag cushion is blockedor restricted from inflating.

In one example, the airbag assembly 40 can include a tethered vent 244.The tethered vent 244 is positioned on a wall of the airbag cushion 46.The tethered vent 244 includes a sleeve 246, a restrictor panel 248 anda vent tether 250. The vent tether is connected to the restrictor panel248 and to a wall 252 of the airbag cushion 46. The tethered vent 244includes one or more holes 254 that extend through the sleeve 246 andthe airbag cushion 46. The sleeve 246 is connected to the airbag cushion46 around an outer edge of the sleeve 246. The restrictor panel isconnected to the sleeve on an end opposite the tethered vent 244. Asshown in FIG. 18A, in the open position, the restrictor panel 248 ispositioned away from the holes 254 such that gas can flow through theholes 254. The restrictor panel 248 is in a folded position and can beheld in place by some tack stitches or other mechanical attachment (notshown). As shown in FIG. 18B, in the closed state, the restrictor panel248 has been pulled by the vent and has moved to cover the holes 254such that gas is restricted from flowing through the holes 254.

The tethered vent 244 moves from the open position (as shown in FIG.18A) to the closed position (as shown in FIG. 18B), when the airbagcushion 46 inflates from the uninflated state to the inflated state.When the airbag cushion 46 is in the uninflated state, the vent tether250 has slack such that it does not exert a force sufficient to move therestrictor panel 248. As such, the restrictor panel 248 remains in theposition away from the holes 254. When the airbag cushion 46 inflates,the wall 252 moves away from the sleeve 246. As the wall 252 moves awayfrom the sleeve 246, the vent tether 250 exerts a force on therestrictor panel 248 in a direction toward the holes 254. The venttether 250 pulls the restrictor panel 248 over the holes 254 in thesleeve 246 when the airbag cushion 46 inflates to the inflated position.In the closed position, gas inside the airbag cushion 46 is restrictedfrom flowing out of the holes 254. The tethered vent 244 can be used tolimit or restrict the airbag cushion 46 from inflating if the airbagcushion 46 is blocked by an object in its deployment path.

In another example, the airbag assembly 40 can include an electronic orpyrotechnic vent 256. In one example, the pyrotechnic vent 256 caninclude a body 258, an arm 260, an initiator 259 and a cover panel 262.The pyrotechnic vent 256 can be mounted to the airbag cushion 46 or tothe airbag housing 42. The pyrotechnic vent 256 is mounted adjacent ahole 264. The hole 264 extends through the airbag housing 42 and/or theairbag cushion 46 to permit gas to flow through the hole 264 when thepyrotechnic vent 256 is in the open state (as shown in FIG. 19A). Asshown, the arm 260 projects away from the body 258 and positions thecover panel 262 away from the hole 264.

When the pyrotechnic vent 256 in the closed position, the arm 260positions the cover panel 262 such that the cover panel 262 covers thehole 264. In the closed position (as shown in FIG. 19B), gas isrestricted from flowing through the hole 264. In one example airbagassembly 40, the pyrotechnic vent 256 is initially positioned in theclosed state. When the pyrotechnic vent 256 receives a control signal,the pyrotechnic vent 256 deploys the initiator 259. The initiator 259expands in the body 258 and causes the arm 260 to move out of (or away)from the body 258 to move the cover panel 262 away from the hole 264such that gas is permitted to escape through the hole 264.

The pyrotechnic vent 256 (or other electronically-controlled vent) canbe connected to a control unit (not shown) that controls the operationof the pyrotechnic vent 256. In one example, the control unit can send asignal to the pyrotechnic vent 256 that causes the pyrotechnic vent 256to move from the closed position to the open position after apredetermined amount of time has elapsed after the airbag assembly hasinflated the airbag cushion 46 from the uninflated state to inflatedstate. In another example, the control unit can send a signal to thepyrotechnic vent 256 that causes the pyrotechnic vent 256 to move fromthe closed position to the open position after a door of the vehicle 20has been commanded to be opened. Such venting of the airbag cushion 46may be desirable to permit the occupant 30, 32 to exit (or be removed)from the vehicle 20 after the airbag cushion has been inflated.

In other examples of the airbag assembly 40, the principles and elementsof the present disclosure can be used in airbag assemblies with shapesand configurations different from those previously described. FIGS.20-22 show various other example configurations of airbag assemblies inaccordance with the present disclosure. As shown in FIG. 20, an airbagassembly 270 can include an airbag housing 272, an inflator 274 and anairbag cushion 276. The airbag assembly 270 is positioned in the roof278 of a vehicle. When the airbag cushion 276 inflates to the inflatedstate, the airbag cushion 276 is positioned in front of an occupant 280seated in a seat 282. In this example, the airbag cushion 276 is angledtoward the occupant 280. The example airbag cushion 276 includes atether 288 that wraps around the airbag cushion 276. The airbag cushion276 also includes a door reaction foot 290. The door reaction foot 290,in this example, projects outward from the airbag cushion 276 at thebottom portion of the door 286.

As shown in FIG. 21, this example airbag cushion 276 includes a roundedshape with a void 292. In this example, the void 292 is positionedbetween a forward portion 296 and a rearward portion 298 of the airbagcushion 276. The forward portion 296 and the rearward portion 298 areseparated by a gap that is located at or above a head of the occupant280. The gap causes the void 292 to be discontinuous, in this example.

Referring now to FIG. 22, another example airbag assembly 40 is shown inan arrangement of the vehicle 20 in which the first occupant 30 isfacing the second occupant 32. In this example, a first airbag cushion306 is shown in the inflated state. The first airbag cushion 306includes a wrap tether 308 that extends from the roof 22 of the vehicleand wraps around a side of the airbag cushion 306 positioned away fromthe occupant 30. A second airbag cushion 310 is also shown in theinflated state. The second airbag cushion 310 is similar to the firstairbag cushion 306 and includes a wrap tether 312 that extends from theroof of the vehicle 20 and wraps around the second airbag cushion 310positioned away from the occupant 32.

The first airbag cushion 306 and the second airbag cushion 310 arepositioned such that lower portions 314, 316 of the first and secondairbag cushions 306, 310 are located closer to the occupants 30, 32,respectively, than the upper portions 318, 320. In this manner, theheads of the occupants 30, 32 can rotate relative to the torsos of theoccupants 30, 32 to reduce the forces and moments on the necks of theoccupants 30, 32 when the occupants contact the first and second airbagcushions 306, 310. In addition, the wrap tethers 308, 312 limit orrestrict the movement of the airbag cushions 306, 310 from moving in adirection away from the occupants 30, 32, respectively. In addition, thewrap tethers 308, 312 are attached at the roof 22 at a horizontalposition closer to the occupant 30, 32 than the location where theairbag cushions 306, 310 are mounted at the roof 22. In this position,the location of the attachment of the wrap tethers 308, 312 areseparated from the airbag cushions 306, 310 along the roof 22. The wraptethers 308, 312 can be positioned on (and attached to) the airbagcushion 306, 310 on a back surface or partially on a bottom surface asshown in FIG. 22.

The foregoing description is merely illustrative in nature and is in noway intended to limit the disclosure, its application, or uses. Thebroad teachings of the disclosure can be implemented in a variety offorms. Therefore, while this disclosure includes particular examples,the true scope of the disclosure should not be so limited since othermodifications will become apparent upon a study of the drawings, thespecification, and the following claims. It should be understood thatone or more steps within a method may be executed in different order (orconcurrently) without altering the principles of the present disclosure.Further, although each of the embodiments is described above as havingcertain features, any one or more of those features described withrespect to any embodiment of the disclosure can be implemented in and/orcombined with features of any of the other embodiments, even if thatcombination is not explicitly described. In other words, the describedembodiments are not mutually exclusive, and permutations of one or moreembodiments with one another remain within the scope of this disclosure.

Spatial and functional relationships between elements (for example,between modules, circuit elements, semiconductor layers, etc.) aredescribed using various terms, including “connected,” “engaged,”“coupled,” “adjacent,” “next to,” “on top of,” “above,” “below,” and“disposed.” Unless explicitly described as being “direct,” when arelationship between first and second elements is described in the abovedisclosure, that relationship can be a direct relationship where noother intervening elements are present between the first and secondelements, but can also be an indirect relationship where one or moreintervening elements are present (either spatially or functionally)between the first and second elements. As used herein, the phrase atleast one of A, B, and C should be construed to mean a logical (A OR BOR C), using a non-exclusive logical OR, and should not be construed tomean “at least one of A, at least one of B, and at least one of C.”

None of the elements recited in the claims are intended to be ameans-plus-function element within the meaning of 35 U.S.C. § 112(f)unless an element is expressly recited using the phrase “means for,” orin the case of a method claim using the phrases “operation for” or “stepfor.”

What is claimed is:
 1. An airbag assembly for mounting above an occupantin a vehicle, the airbag assembly comprising: an airbag housing; and anairbag cushion connected to the housing and deployable from anuninflated state to an inflated state, the airbag cushion including aforward portion and a rearward portion, the forward portion positionedcloser to the occupant than the rearward portion when the airbag cushionis in the inflated state, the forward portion separated from therearward portion by a void, the void configured to cause a head of theoccupant to rotate forward relative to a torso of the occupant when theoccupant contacts the airbag cushion.
 2. The airbag assembly of claim 1wherein the airbag housing is configured to mount to a roof of thevehicle and the airbag cushion deploys downward to a position in frontof the occupant and the forward portion curves back toward the rearwardportion when the airbag cushion moves from the uninflated state to theinflated state such that a side profile of the airbag cushion has aJ-shape.
 3. The airbag assembly of claim 1 wherein the airbag cushionincludes a lower portion connecting the forward portion to the rearwardportion, the lower portion positioned lower than the forward portionrelative to the occupant when the airbag cushion deploys to the inflatedstate.
 4. The airbag assembly of claim 3 wherein the airbag cushionincludes an inflating leg that projects downward from the forwardportion, the leg positioned below the lower portion relative to theoccupant when the airbag cushion is in the inflated state.
 5. The airbagassembly of claim 3 wherein the forward portion is connected to therearward portion at a side of the void opposite to the lower portion. 6.The airbag assembly of claim 3 wherein the lower portion is positionedcloser to the occupant than a top of the forward portion when the airbagcushion is in the inflated state such that the head of the occupantrotates forward relative to the torso of the occupant when the occupantcontacts the airbag cushion.
 7. The airbag assembly of claim 1 with aninflating upper portion positioned above the void, the inflating upperportion connecting the forward portion to the rearward portion.
 8. Theairbag assembly of claim 1 wherein: the airbag cushion includes a firstpanel that defines an inner surface of the airbag cushion adjacent thevoid and a second panel that defines an outer surface of the airbagcushion and is joined to the first panel, the first panel and the secondpanel defining a central chamber of the airbag cushion; the first panelis made of a woven fiber material having fibers oriented parallel to andperpendicular to a longitudinal direction of the airbag cushion; and thesecond panel is made of the woven fiber material having fibers orienteddiagonally with respect to the longitudinal direction of the airbagcushion.
 9. The airbag assembly of claim 2 wherein the airbag cushionincludes an attachment tab that connects a terminal end of the forwardportion to the rearward portion to maintain the side profile of theairbag cushion.
 10. The airbag assembly of claim 1 wherein the airbagcushion includes a plurality of longitudinal chambers configured tostiffen the airbag cushion.
 11. The airbag assembly of claim 1 whereinthe airbag cushion includes a first panel positioned opposite to asecond panel, the first panel and the second panel forming a recessedportion between a first longitudinal chamber and a second longitudinalchamber, the recessed portion having a first inflated thickness that isless than a second inflated thickness of the first and secondlongitudinal chambers when the airbag cushion deploys to the inflatedstate.
 12. The airbag assembly of claim 11 wherein the recessed portionof the airbag cushion remains uninflated when the airbag cushion deploysto the inflated state.
 13. The airbag assembly of claim 11 wherein thefirst panel and the second panel of the airbag cushion further define atleast one inflating rib that laterally connects the first longitudinalchamber to the second longitudinal chamber.
 14. The airbag assembly ofclaim 1 wherein the airbag cushion includes a tether connecting theforward portion to the rearward portion to limit a distance between theforward portion and the rearward portion.
 15. The airbag assembly ofclaim 1 wherein the airbag cushion includes a first panel, a secondpanel and an internal tether, the first panel and the second panelpositioned opposite to one another to define a central chamber of theairbag cushion, the internal tether connected between the first paneland the second panel inside the central chamber to define a size of theairbag cushion when the airbag cushion deploys to the inflated state.16. The airbag assembly of claim 1 wherein the airbag cushion includes avoid-shaping tether, the void-shaping tether connecting the forwardportion to the rearward portion on opposite sides of the void to definea size of the void when the airbag cushion deploys to the inflatedstate.
 17. The airbag assembly of claim 1 wherein: the airbag cushionincludes a first panel and a second panel, the first panel and thesecond panel positioned opposite to one another to define a centralchamber of the airbag cushion; the airbag cushion further including atleast one of a corner tether and a bend tether, the corner tetherpositioned in the void at a curved portion of the airbag cushion, andthe bend tether connected between the first panel and the second panelat a curved portion of the airbag cushion; and the at least one of thecorner tether and the bend tether causes the airbag cushion to have apredetermined shape when the airbag cushion deploys to the inflatedstate.
 18. The airbag assembly of claim 1 comprising at least one of atethered vent and a pyrotechnic vent.
 19. The airbag assembly of claim 1comprising an airbag vent configured to move from a closed position toan open position when a predetermined amount of time has elapsed sincethe airbag cushion deployed to the inflated position or a door of thevehicle is opened.
 20. The airbag assembly of claim 1 further comprisinga tethered vent that is configured to move from an open position to aclosed position when the airbag cushion inflates to the inflated stateand to not move from the open position to the closed position when anobstacle prevents the airbag cushion from inflating to the inflatedstate.